Electric secondary battery



Oct. 17, 1939. L. FULLER ET AL ELECTRIC SECONDARY BATTERY AQu.

I/nenorf.' El?" Flled Deo Patented Oct. 17, 1939 UNITED STATES PATENT OFFICE ELECTRIC SECONDARY BATTERY Leonard Fuller, London, and Edmund William Sudlow, Ilford, England Application December 17, 1938, Serial No. 246,436 In Great Britain August 21, 1937 Claims. (Cl. 13G-4i) This invention relates to electric Secondary material possesses these essentials in the required batteries, and in particular, to the so-called dry degree the thickness of their application becomes type of secondary battery wherein the electrolyte of secondary importance limited only by the meis completely absorbed in the electrodes coniointly chanical strength and elasticity of the separating 5 with a porous medium surrounding and separatlayer or coating. 6 ing said electrodes. Suitable separating materials are known which The object of this invention is to provide imconsist of powdered pumice, kieselguhr or the provements in the manufacture and construction like substances, mixed with electrolyte to form a of such batteries whereby an increased capacity paste which may be applied by any convenient l0 per unit bulk or weight is obtained, and means means. 10 also whereby this increased capacity is main- Animproved secondary battery of the so-called tained during the life of the battery, whether it dry type may be constructed by coating or combe left standing for long inactive periods or subpletely covering the compressed negative and jected to a large number of charging and dlspositive electrodes with alayer of separator matecharging cycles, or whether it be subjected to abrial, such as those above described, and subjecting 15 normal charging rates. them to pressure so as to exclude all air and free Previously suggested batteries of the dry secelectrolyte from the plate or grid block and inondary type have been found to lose their casorting the whole into a container made of suitpacity under any of the above-mentioned condiable material, such as for example ebonite, glass,

tions at a rate and in a degree approximately or synthetic resin condensation product or the 20 proportionate to their solidity and recent research like. The exposed surface of the coated elecin connection with batteries of this type has trodes is then completely covered with a layer of disclosed that their capacity per unit bulk or powdered or granular material, such as sand,

Weight may be considerably increased by ensurwhich is then compressed and covered in turn ing that the manufactured battery shall be as with a layer of pitch, or other suitable matecompact as possible and contain no air or free rial, leaving only a space for a vent which is electrolyte, and, moreover, that such an increase pressed into close contact with the sand surface in capacity may be maintained during the later and which is provided with a perforated lead life of the battery by providing means in its conplate or gauze at its lower extremity so as to pre- :zn struction whereby a conservation of its internal vent the escape of any particles of the granular pressure is obtained and its constant optimum material whilst still permitting free passage for solidity is assured. In a method of producing a the gases. so-called dry secondary battery of the type com This layer o1' pitch, while still soft or senilprising, in a container, positive and negative hardened, is then covered with a lid of ebonite, or

electrodes, the active materials of which substanother suitable material, and the whole is sub- 86 tially absorb all of the electrolyte conjointly with lected to pressure and retained in the position a porous separator surrounding said electrodes, obtained by locking the ebonite lid with the outer the present invention is characterized by the fact container in any suitable manner. that the battery is constructed under sumcient Complete solidity having now been obtained, a

pressure to exclude all air and/or free electrolyte nal layer of pitch is applied to effect optimum 40 therefrom, and that one or more sealing layers sealing. substantially prevent subsequent movement of As an added safeguard against the escape of the internal structure of the battery, said sealing granular particles from the sand surface, which layer or layers being provided with positive lockif not prevented would cause a loosening of the ing means to maintain the solidity of the cell. internal construction and a resultant loss oi' eiii-a 45 In view of the necessity of obtaining complete ciency, the vent passage may be lled with glasssolidity with an absence of air or free electrolyte wool or like material held in position by an upper it is important that more than ordinary care and lower lead screen or gauze as will be hereinshould be exercised in the selection of materials after described.

o for the separator. In a further modification of this invention the 50 'I'he primary considerations which should govvent may be provided with means whereby spare ern this selection are the iiexibllity ot the matewater may be carried on the battery so that the rial, its porosity, and its ability to prevent contact replacement of water which is necessitated by the between `the negative and positive electrodes or gaseous evolution may be performed either autoparticles therefrom at al1 times. If the selected matically or manually at predetermined intervals. 5o

ICI

By these means one of the primary causes of automobile starter battery breakdown, namely lack of water or electrolyte during operation, may be eliminated and the battery kept at its optimum eflciency.

This modification may be carried into eect in a variety of ways, a suggested method being to provide a hollow or cup-like vent with a screwtop, a hole being provided in said top to allow the gases to escape, the upper or cup-like portion of the vent being capable of containing suflicient spare water to provide for the requirements of the battery over fairly extensive periods. By this method the replacement of water continues proportionately to the rate of evaporation and gaseous evolution, so that the battery receives automatic attention until the cup becomes emptied.

Another means whereby a similar effect may be obtained would be to provide a hollow waterfilled vent, milar to the above type, but differing therefrom in that it is also provided with a hollow plunger tube which, when depressed, permits the release of the desired amount of water to compensate for the loss through gaseous escape which latter occurs unhindered through the hollow tube.

This principle may be further modified according to this invention by placing the cup or container portion of the vent below the uppermost layer of pitch so that it may thus extend over almost the whole horizontal surface area of the battery. The spare water in this case would be admitted through the normal vent orifice, and the sealing provided by the superimposed layer of pitch would prevent leakage and still permit the battery to be used in any position, which is one of the features of this type.

A typical secondary battery of the so-called dry type made in accordance with this invention is hereafter described with reference to the accompanying drawing, which is included as explana tion and is not intended to limit the invention thereto, in which drawing:

Figures l and 2 are sectional side and end elevations respectively of a plate type battery;

Figure 3 is a fragmentary perspective view, exploded to show the details of the locking means in Figures 1 and 2;

Figure 4 is a similar view showing a modified arrangement;

Figure 5 is a sectional elevation of another form of battery having concentric electrodes; and

Figures 6 and 'l are sectional elevations to an enlarged scale showing alternative forms of vents arranged to carry spare water.

In Figures 1 and 2, an outer container, IU, made of ebonite contains the pasted and compressed negative and positive electrodes, II and I2 respectively, which have each been coated upon all their surfaces with a layer of porous separator material, I3, such as powdered pumice, kieselguhr or the like mixed with electrolyte to form a paste, and then packed together under pressure so as to form an air-free block completely covered with separator material. This block is designed to fit into the container III as tightly as possible, allowing only space for convenient assembly, and all spaces around the block and up to the tops of the usual terminal bridges, I4, are lled with separator material under pressure so that all air is excluded and no free electrolyte is present.

A layer of sand, I5, is then applied to the upper or exposed surface of the separator material and highly compressed, whereupon a vent, I6, provided at its lower end with a cap of perforated lead or gauze, I1, is forced into close contact with the sand, so that that particular area of sand which is immediately below the vent I6 and which is ordinarily subject to disintegration because the gases are evolved at that point, is always kept compressed and undisturbed. A layer of pitch, I8, is then applied to the remaining portion of the sand surface and is allowed to harden partially. When this pitch layer is in the desired condition, a lid of ebonite I8, provided with two or more lugs 20 (see Figure 3), which are adapted to slide in slots 2|, situated in the corresponding inner surfaces of the outer container, IU, is superimposed thereon and the whole is subjected to pressure, whereupon the lugs 20 of the ebonite plate reach the lowest extremity of the slots 2| and are thereafter held in that position by inserting separate pieces of ebonite 22 into transverse slots 4I. The ebonite lid I9 is then nally covered with another layer of pitch 23, so that a completely solid and air-free cell is obtained.

Another improved method of obtaining this positive sealing and maintenance of rigidity in connection with this type of battery is sho'wn in Figure 4, wherein a cylindrical sleeve of ebonite, 24, is provided with a tongue or lug 25 extending radially from its base, and is adapted to fit pivotally over each terminal Il and rest upon the ebonite lid i9, which is in position on the lower pitch layer, so that when pressure is applied to the ebonite lid its final position may be retained by turning the ebonite sleeve 24, until the lug 25 thereon engages within the transverse slot 26, formed in the corresponding inner surfaces of the outer container i0.

The application of the foregoing principles to a small secondary cell of the so-called dry type is shown in Figure 5, wherein a cylindrical outer container Illa, is made of lead, and is pasted internally with negative active material 21, the latter being coated with a layer of porous separator material, indicated at I3a. A positive electrode comprises a central lead core 28 surrounded with finely divided positive active material 29 which is rammed or compressed against the separating layer I 3a and the positive core 28 under the iniluence of a pressure which is sufficient to ensure complete absence of air, or pockets where free electrolyte can accumulate. A layer of sand lia is then applied to the exposed surfaces of the separator i3d and positive active material 29 and compressed. A layer lila of pitch is then applied to the sand surface, leaving only space for a vent 30 which is in close contact with the sand for the purpose aforesaid. As in the plate type battery this pitch layer Ia is allowed to partially harden before receiving an ebonite lid I9a, and after pressure is applied to said ebonite lid the position thus obtained is held and locked against subsequent movement by rst forming a corrugatlon III adjacent the top of the outer container Illa and above the ebonite lid ISa, and then rolling over the upper edge of the outer container Ia until it meets the exposed surface of the ebonite lid I9a. The inner surfaces of this rolled edge or beading may be perforated so that when the ilnal layer of pitch 23a is applied it may flow into the interior of the beading as shown and cover the remaining portion of the ebonite surface thus assisting in the positive locking of the lid Isa.

By these methods a secondary cell is produced which is substantially dry and completely solid and air-free, and which, therefore, possesses considerably increased capacity and the ability to maintain same for long periods even when severely mishandled electrically.

An improved form of vent according to this invention is shown in Figure 6, in which a hollow or cup-like container, 32, is adapted to accommodate spare water and is fitted with a screw-top 33 provided with a hole 34 therein to allow the gases to escape without hindrance. The lower end of the vent is formed with a stem 35 having at its upper and lower ends, caps 38 of perforated lead or gauze, which may, if desired, enclose a loose pad of glass-wool 31, so as to allow free passage for the gases whilst still preventing the escape of any granular particles from the sand surface in order to preserve the internal rigidity of the cell.

A slightly modiied form of vent is shown in Figure 7. In this case a tubular plunger 38 is provided at its upper end with a knob or button 39, and at its lower extremity with a springloaded valve 40, clearance being allowed between the plunger 38 and the bottom of the container 32, so that, when the knob 39 is depressed, the valve Il) opens to permit the water to flow into the cell to replace the loss of water caused by the evolution of gases. Free passage for the gases is always provided through the hollow plunger 38 and a corresponding hole in the knob 39.

What we claim is:

l. In a secondary battery comprising a casing completely filled with electrodes and separating material, non-conductive material covering the upper surface of the lllng comprising the electrodes and separating material for sealing said filling within the casing a rigid closure for maintaining said filling under pressure within said casing, locking means cooperating with said closure and casing for maintaining said closure in position, and a vent extending through said closure and in contact with the upper surface of said lling, said vent having means for preventing the passage of solid substances but permitting the passage of gases and liquids.

2. In a secondary battery comprising a casing a filling within said casing comprising electrodes and separating material, and a closure sealing said illling within said casing, a vent extending through said closure and in contact with the upper surface of said iilling, said vent comprising a reservoir for containing compensating electrolyte, a valve for controlling the passage of said electrolyte to said battery filling, said valve having a channel extending therethrough to pass gases outwardly at all times, and means in the vent for preventing the passage of solid particles but permitting the passage of gases and liquids.

3. A so-called dry secondary battery comprising a casing, a filling within said casing which comprises a positive electrode and a negative electrode, porous separating material completely filling the remaining space in the casing, a rigid closure member applied under pressure to said filling, and locking means comprising an arm pivotaliy mounted upon a terminal lug carried by one of the electrodes and engaging the closure member, said arm being adapted to enter a recess formed in the interior surface of the casing so as to positively hold the closure member in position and thus maintain the components under compression.

4. A so-called dry secondary battery comprising a casing, a iilling within said casing which comprises a positive electrode and a negative electrode, porous separating material completely filling the remaining space in the casing, a layer of porous, non-conductive material covering the upper surface of the electrodes and separating material, liquid electrolyte wholly absorbed by the electrodes, a rigid closure member applied under pressure to said lling, and locking means comprising a projection formed upon the closure member and arranged to engage with a recess in the casing, a locking member adapted to engage laterally extending recesses in the casing to lock the projection within its recess and hold the closure member in position whereby to maintain the components of the battery under pressure.

5. A so-called dry secondary battery comprising a casing, a filling within said casing which comprises a positive electrode and a negative electrode, porous separating material completely filling the remaining space in the casing, a rigid closure member applied under pressure to said filling, and locking means comprising an inwardly directed corrugation formed in the casing to overlie the edges of the closure member and the edges of the casing being formed over to bear against the closure member to hold said closure member in position so as to maintain the components under pressure, and thermoplastic material overlying the closure member and surrounding the turned over edges.

LEONARD FULLER. IHJMUND WILLIAM SUDLOW.

CERTIFICATE OF CORRECTION.

Patent No. 2,176,175.

October l?, 1959.

LEONARD FULLER, ET AL. It is hereby certified that error appears in the printed specification of the above numbered patent requiring correction as follows: Page 5, second column, lines 2li to 2B inclusive, claim l1.,

strike out the words and comma "a layer of porous, non-conductive material covering the upper surface of the electrodes and separating material, liquid electrolyte wholly absorbed by the electrodes,"; and that the said Letters Patent should be read with this correction therein that the same may conform to the record of the case in the Patent Office.

Signed and sealed this th day of December, A. D. 1959.

(Seal) Henry Van Arsdale,

Acting Commissioner of Patente.

siderably increased capacity and the ability to maintain same for long periods even when severely mishandled electrically.

An improved form of vent according to this invention is shown in Figure 6, in which a hollow or cup-like container, 32, is adapted to accommodate spare water and is fitted with a screw-top 33 provided with a hole 34 therein to allow the gases to escape without hindrance. The lower end of the vent is formed with a stem 35 having at its upper and lower ends, caps 38 of perforated lead or gauze, which may, if desired, enclose a loose pad of glass-wool 31, so as to allow free passage for the gases whilst still preventing the escape of any granular particles from the sand surface in order to preserve the internal rigidity of the cell.

A slightly modiied form of vent is shown in Figure 7. In this case a tubular plunger 38 is provided at its upper end with a knob or button 39, and at its lower extremity with a springloaded valve 40, clearance being allowed between the plunger 38 and the bottom of the container 32, so that, when the knob 39 is depressed, the valve Il) opens to permit the water to flow into the cell to replace the loss of water caused by the evolution of gases. Free passage for the gases is always provided through the hollow plunger 38 and a corresponding hole in the knob 39.

What we claim is:

l. In a secondary battery comprising a casing completely filled with electrodes and separating material, non-conductive material covering the upper surface of the lllng comprising the electrodes and separating material for sealing said filling within the casing a rigid closure for maintaining said filling under pressure within said casing, locking means cooperating with said closure and casing for maintaining said closure in position, and a vent extending through said closure and in contact with the upper surface of said lling, said vent having means for preventing the passage of solid substances but permitting the passage of gases and liquids.

2. In a secondary battery comprising a casing a filling within said casing comprising electrodes and separating material, and a closure sealing said illling within said casing, a vent extending through said closure and in contact with the upper surface of said iilling, said vent comprising a reservoir for containing compensating electrolyte, a valve for controlling the passage of said electrolyte to said battery filling, said valve having a channel extending therethrough to pass gases outwardly at all times, and means in the vent for preventing the passage of solid particles but permitting the passage of gases and liquids.

3. A so-called dry secondary battery comprising a casing, a filling within said casing which comprises a positive electrode and a negative electrode, porous separating material completely filling the remaining space in the casing, a rigid closure member applied under pressure to said filling, and locking means comprising an arm pivotaliy mounted upon a terminal lug carried by one of the electrodes and engaging the closure member, said arm being adapted to enter a recess formed in the interior surface of the casing so as to positively hold the closure member in position and thus maintain the components under compression.

4. A so-called dry secondary battery comprising a casing, a iilling within said casing which comprises a positive electrode and a negative electrode, porous separating material completely filling the remaining space in the casing, a layer of porous, non-conductive material covering the upper surface of the electrodes and separating material, liquid electrolyte wholly absorbed by the electrodes, a rigid closure member applied under pressure to said lling, and locking means comprising a projection formed upon the closure member and arranged to engage with a recess in the casing, a locking member adapted to engage laterally extending recesses in the casing to lock the projection within its recess and hold the closure member in position whereby to maintain the components of the battery under pressure.

5. A so-called dry secondary battery comprising a casing, a filling within said casing which comprises a positive electrode and a negative electrode, porous separating material completely filling the remaining space in the casing, a rigid closure member applied under pressure to said filling, and locking means comprising an inwardly directed corrugation formed in the casing to overlie the edges of the closure member and the edges of the casing being formed over to bear against the closure member to hold said closure member in position so as to maintain the components under pressure, and thermoplastic material overlying the closure member and surrounding the turned over edges.

LEONARD FULLER. IHJMUND WILLIAM SUDLOW.

CERTIFICATE OF CORRECTION.

Patent No. 2,176,175.

October l?, 1959.

LEONARD FULLER, ET AL. It is hereby certified that error appears in the printed specification of the above numbered patent requiring correction as follows: Page 5, second column, lines 2li to 2B inclusive, claim l1.,

strike out the words and comma "a layer of porous, non-conductive material covering the upper surface of the electrodes and separating material, liquid electrolyte wholly absorbed by the electrodes,"; and that the said Letters Patent should be read with this correction therein that the same may conform to the record of the case in the Patent Office.

Signed and sealed this th day of December, A. D. 1959.

(Seal) Henry Van Arsdale,

Acting Commissioner of Patente. 

